POLCA Approach on Make to Order Production System: An Application from the Hydraulic Industry

Köse Y., Çevikcan E., Celik S. R.

Global Joint Conference on Industrial Engineering and Its Application Areas (GJCIE), ELECTR NETWORK, 14 - 15 August 2020, pp.121-134 identifier

  • Publication Type: Conference Paper / Full Text
  • Doi Number: 10.1007/978-3-030-76724-2_10
  • Page Numbers: pp.121-134
  • Keywords: POLCA system, Make-to-order, Simulation, Hydraulic industry, WIP
  • Istanbul Technical University Affiliated: Yes


Applications of production control systems such as pull systems, which are also called Kanban control systems have attracted attention not only in the field of production but also in the academic world. Suri (1998) has introduced a different production control system to ensure attractiveness in production systems with high product variety: Paired-cell Overlapping Loops of Cards with Authorisation (POLCA) production control system. The POLCA system aims to ensure the effective use of the pull system in a wide variety of products and in a low volume. In the literature, the POLCA system has been examined for make-to-order systems (MTO), but its advantages have not been seen clearly. In MTO systems, the simulations are not fully understood, and the comparisons may not yield clear results. In this paper, a more general perspective on the design issues in the POLCA system has been introduced, and the tools and methods that can be understood by the people who are not licensed and who manage the production company have been summarized. Within this paper, the definition of POLCA is mentioned first. Then the industrial application area and conditions of use have touched on. The current and proposed examining the advantages and disadvantages of the systems, the basic calculations, and researches on the shaping of the production line according to the proposed POLCA system have been presented.